Sound deadening structure



May 1935- G. D. KELLOGG 2,001,733

SOUND DEADENING STRUCTURE Filed Jan. 2, 1952 2 Shets-Sheet 1 H INVENTOR Geo/ye D. Kelloj ATTORNEY 4 May 21, 1935. D. KELLOGG SOUND DEADENING STRUCTURE Filed Jan. 2, 1932 2 Sheets-Sheet 2 e17. [fella I ATTORNEY INVENTOR :9 9%

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Patented May 21, 1935 PATENT, OFFICE SOUND DEADENING STRUCTURE George D. Kellogg, Pelham Manor, N. Y., assignor to Johns-Manville Corporation, New York, N. Y., a corporation of New York Application January 2, 1932, Serial No. 584,446

8 Claims.

This invention relates to a structure adapted for use in a roof or side wall of a building. It

, pertains especially to a structure in which sounddeadening material is maintained in position over or behind a perforated metal sheeting in the form of a rigid, large unit and is protected on the outer side against the penetration of water. A preferred embodiment of the invention is-a relatively inexpensive, fire-resistant roof structure comprising a perforated metal deck with upwardly extending integral beams, such as ribs, a sound-deadening material in position above the perforations, and a protecting superstructure adapted to coact with the sound-deadening material in such manner as to preserve the latter in effective condition.

An object of the invention is to adapt a usual type of roof structure, including a metal deck, to sound deadening. Another object is to provide an inexpensive and relatively rigid roof or side wall, that .is sound-deadening and suitably also thermal insulating and fire-resisting. A further object is to improve the sightliness of a roof containing ribbed sheet metal, known as a metal deck, by reversing, in some cases, the conventional position of the ribs,-that is, by causing them to extend upwardly instead of downwardly, and thus exposing in the interior of the building the flat portion of the metal deck, with preservation of the rigidity imparted in the conventional construction by the downwardly extending reenforcing ribs. Other objects and advantages will appear from the detailed description that follows.

To provide a light-weight, fire-resistant thermal insulating roof deck of sufiicient structural strength vto permit application over fairly large spans in steel buildings, sheet metal has deck sheets are applied.

In general practice these metal deck sheets are made of copper-bearing steel and are applied with the ribbed side down and exposed in the interior of a building. The ribs are clipped, bolted,

welded at intervals, or otherwise fastened to the steel purlins. End joints between roof deck sheets are lapped, as are also the side joints, whereby there is formed an interlocking, continuous roof construction. A roofing material may be applied on the outside, that is, to the flat steel plates, by cementing it to the surface with hot asphalt or pitch. Or, an insulated roof may be provided by first cementing and/or clipping one or more sheets of an insulating board to the fiat steel deck and then applying to the upper surface of the insulating board a built-up roofing, such as asphalt-impregnated asbestos paper, the various layers of the paper being cemented to the insulating board or to each other by means of asphalt or pitch applied in hot condition.

This type of construction is in common use as a roof in many buildings where light weight steel construction and heat insulation are desirable. There is used occasionally also some kind of acoustical treatment or sound-deadening interior finish on the ceilings. The application of such acoustical treatment has involved heretofore an extra operation and expense after the roof, deck and roofing have been installed. Usually there has been required the erection of scaffolding and means of supporting the sounddeadening material.

The present invention provides for the. support of the sound-deadening, that is sound-absorbing material, the heat insulating material,

perforated properly. Perforations made in acy cordance with U. S. Patent No. 1,726,500 to Norris are satisfactory. Norris describes a sounddeadening structure adapted to be applied to the under side of a ceiling.

The present invention is illustrated by the drawings.

Figs. 1-9 show perspective views of various embodiments of the invention. The embodiment which is preferred at this time is that illustrated in Fig. 1.

In the various figures, like reference characters indicate like parts.

Thus there is illustrated a metal deck provided with perforations I adapted to admit incident sound and with integral beams in the form of reenforcing ribs. The deck is in the form of sections provided each with a plurality of imperforate reenforcing ribs. The ribs preferably ex- 1 2,001,738 tend upwardly in the case of a ceiling construc- In cases where tion as illustrated in severalof the figures, and in the direction or the flat portion the metal outwardly in the case oi a side wall construction deck, as illustrated in the hollow rib construction The ribs may have blips 3 welded to the ribs or A 1 maintain, in position, panels 5 of sound-deadenillustrated in Fig.6. The ribs extend in approxiof Fig. 3, for example, the sound-deadening mamately parallel directions and are provided with terial may be wedged in or dovetailed in; between side walls 4 and a base 2 or portion remote from the sloping sides ofthe ribs. with rigid sound- =the flat portion of the roof deck. In some cases deadening panels with beveled edges II, this the ribs have sides 4 converging the base is wider than the part of the rib joined wedging in or dovetailing adds rigidity to the to or adjacent to the flat portion ofihe rooi deck. structure. However, this dovetailing "isi jusually This is-illustrated in Figs. 1; 2; 3, 6, '7 and 9, in unnecessary and a more convenient'method' of which cases the ribs are hollow or approximately inserting the panels is preferred. For convenient Fig. 4, in which'case the ribs are provided with than that of the most narrow part of the openflanges i2 extending from the edge of the rib ingbetween two adjacentribs, as illustrated in .remote from the flat portion of .the roof deck; Figs. 1 and 8. j

Ribs with flanges l2 extending from the edge of may consist of tongues of metal punched out from the rib remote from the flat portion of the roof the rib. These clips are adapted to engage or deck are illustrated in Fig. 4.

A roof construction in which the reeniorcing ing material inserted between the said ribs; as ribs of the metal deckhave relatively straight by having the ends of the clips turnedover the sides and nowide portion are illustrated at ll 7 edge of the panels. These panels of sound-deadin Fig. 5. A

Iening material may be placed directly over or deck or may be maintained in spaced relationship thereto by means 'oispacing members in (shown in Fig. 2).

may b eflnished by the application of a layer of finishing material, as, for example, a Portland I Inorder to maintain the sound-deadening ma-' cement layer l5 secured to the expanded metal t r al in ec v co d on a d a so to make the or. chicken wire netting which, in turn, is seroof. structure thermal insulating and watercured to the ribs of a metal deck similar to that triangular incross section. and illustrated alsoin insertion the panel may have width no greater The adaptation of the structure of the present I behind the perforated flat portion of the metal invention to a side wall of a building is illustrated in Fig. 6. Here the outer surface of the structure tight, the metal deck and the panels oi-sound usedin construction of a roof. Modifications in deadening material are Protected y sup rp sed which the outer protecting layers are substituted ay of t er al Insu t a wat rpro fin by other material, as, for example, by metal sheetmaterial. These thermal insulatin and watering are illustratedin Figsfland 8'. InFigJ there proofing layersare illustrated in Figs. 1 and!) and is shown a sound-deadening and thermal insulatmay b us d in a iat on with any the subing structure in which sound-deadening material ably in the form or light weight boards of cane ported, directly or indirectly, upo

? adhesive material.

combinations or modifications illustratedin Figs. is in position between the ribs in a pertorated 2-5. Such protective material is ,sunmetal deck, a layerof thermal insulatingmameV ibs. w e eby e structure is dapted to terial and the ribs, and an imperiorate sheet I] withstand ub t ntial l adin ev w en th of structural material, suitably steel, is placed sou d-deade in m terial between the ribs is "over the insulating material. The imperiorate relatively weak. These layers of protective inasheet may be attached to the rest of the structerial. in preferred o m a Shown in tail in .ture in any conventional manner, as, for exam- Figs. land '9 with modifications illustrated in -ple, -by case-hardened self-tapping screws il' Fi s.- 7 and 8 Any of hese protective m erial which may be driven through the sheet and into r be in a ati wi an c i the su the ribs. The use of the layer or thermal insu- Wmbinfltions Shown in Figslating material between the ribs and the outer im- Fr m F18- .1111 willebe seen that the roof deck perforate sheeting insures a spaced relationship with inserted sound-deaden ma rial may be between the ribs and the outer sheeting and minicovered with thermal insulating material I, Sui -v mizes the transfer of heat from one to theother.

While the invention has been described as ap- 6 fibers ppl in 3 thickness 0! W0 layers plied to a sound-deadening construction compris- 'with broken joints. j The lower y is h d to e e ei may. be substituted by other spacing members. ribs of the metaldeok and to the 0l de8d as, for. example, by the bolts or studs 20, illusing material between the ribs by securing mean trated in Fig. 8,. The studs shown have nuts on ir my eons! of a thin layer 0! Portlandv each side-of the'plain perforated sheet 19 and 3 6 asphalt pp i 1101? i o o e also of the imperforate water-tight sheet. 20.

Second pp lay r 0! These nuts and the studs maintain the two sheets ing ad ered to the lower layer in spaced relationship and, ii desired, maintain b a mating l which may phfit pitch, also the imperiorate sheet II in spaced relationema ed i hot cond on. o other. adhe ee ship to the sound-deadening material placed he= whole 15 t 00m 3? 3 8 biifltvup tween this sheet and the perforated sheet I9. It

roofing consisting oia number of layers of asphalt-impregnated asbestos paper, rag felt iml with tar, or equivalent material 8 adhered to each other or to the underlying insulating board layers by the adhesive material I.

The metal deck is supported on a substructure or which there is shown only' one purlin The metal deck may be to the purlins or supporting members in any conventional manner, as by welding at intervals, bolts, rivets, or clips of suitable design; I 1

- similar structure illustrated in Fig. 7.

The upwardly extending ribs prevent crush-.

ing of a sound-deadening material by a load on top of the roof. However, if it given root will never carry a load greater than the sound-deadening material can withstand 'withoutcrushing,.in the absence of the loadis known that a imdterial i6 is placed over the sound-deadening ma- 5 ing a ribbed and perforated metal sheet, the ribs material, at the other end. Over the sound-deadening material is placed and adhered protective material, suitably the same structure as illustrated in Fig. 1 and comprising the elements numbered 6,1, 8,-and 9. The construction shown in Fig. 9 may be used also in a side wall'of a building, in which case the ribs extend inwardly and the protecting material, outside 'the sounddeadening material, may comprise the elements H and I5 (Fig. 6) or other water-tight protective material.

The method of making structures or assemblies of the types illustrated should require little or no explanation other than what has been given in connection with the description of. the drawings. The metal'deck is provided in standard form and perforated, as with 1% inch diameter holes on inch centers or in other manner described in the above mentioned patent to Norris. When this perforated metal deck has been installed in the roof of a building, panels, felts, or other form of sound-deadening material, but preferably rigid or semi-rigid panels, are placed over the perforations and, if there are upwardly extending ribs, between the ribs. The panels are maintained in position in any of several different manners. Thus the panels may be maintained in position by clips consisting of thin strips of metal secured to the ribs or to fiat portions of the roof deck and bent over the inserted sound-deadening material, as illustrated in Figs. land 2. Or, the panels may be engaged by tongues provided in the ribs by punching out during the fabrication of the roof deck. The tongues may have points turned at right angles to the rest of the tongue and may be adapted to be in-.

serted, at the point, into panels of sound-deadening material in position between the ribs.. The application of the protective material. such as the insulating board and the built-up roofing, may be made in a usual manner, as has been described. If the panels are to be dovetailed between the ribs, then the panels should be inserted at the end of a section of the rock deck and slipped along to the position desired. While the ceiling structure is supported suitably on steel purlins, the side wall construction may be supported on studding, either metal or wood, but preferably metal .where fireproof construction is desired. By having the studding relatively strong for the width of the studding, the side wall may be supported by the studding without covering a sufficient area of the sound-deadening construction to render unsatisfactory the sound-deadening properties of the side walls. The structures illustrated in Figs. '7 and 8, in which the sounddeadening material is enclosed on the upper or outer side by sheet metal, such as sheet steel, are designed to be assembled preferably during the construction of a building rather than preassembled and installed as a unit.

The propertiesof the structures made in accordance with the invention are such as to adapt them generally for use where relatively inexpensive and rigid sound-deadening, fireproof asphalt-impregnated asbestos paper.

construction of ceiling and/or side walls is desired. A typical construction was found to be light in weight and effective as a sound deadener as well as a thermalv insulator. This constructionwas made of hollow rib, copper-bearing steel fabricated into units 18% inches wide and'of length depending upon the purlin spacing, which may be 5% to 8 feet. The metal deck had hollow ribs of approximately triangular cross section 1 inches deep by 1 inch wide, spaced on 6 inch centers. The metal sheeting was perforated with a multiplicity of holes, each of diameter inch, on approximately inch centers. This perf orated metal roof deck was placed on steel purlins. Semi-rigid panels of standard type 1% inches thick, comprising nodulated rock wool and an asphalt binder so used as to maintain the porosity and permeability to sound of the finished block, were inserted above the perforations and between the ribs. The panels were fastened in place by clips and the whole was then covered by two layers, each inch thick.

of insulating wood fiber board and. protected from water bythe application, over the upper layer of insulating board, of several layers of The insulating. board and the superposed water-tight layers of roofing paper were adhered to each other or to the ribs of the roof deck and the sounddeadening material by means of mopping with hot asphalt. The finished roof, excluding the supportingsubstructure but including the metal roof deck, weighed approximately 6.7 pounds per square foot, absorbed more than 60 per cent of incident sound of approximately 500 cycles freuuency, and was calculated to give a thermal transmittance of less than 0.160 B. t. u. per square foot, per hour, per degree Fahrenheit difference in temperature between the inside and the outside surfaces, at a wind velocity of 15 miles per hour over the exterior surface. It has been calculated also that this roof construction is more effective as a thermal insulator than 20 inches of solid concrete.

In view of the-fact that sound-deadening material loses its effectiveness when the pores therein are closed by water and in view of the fact that a metal roof deck, unless protected by an outer thermal insulating coating, may cause condensation of moisture in the fcrm of dew portance of the outer thermal insulating and protecting material may be readily appreciated. This outer layer, by decreasing the difference of temperature between the metal roof deck and the air below and adjacent thereto, minimizes the condensation ofmoisture as dew, which might otherwise form within the pores of the permeable sound-deadening material, and thereby coacts with the sound-deadening material to maintain it in effective or dry condition. Likewise the built-up roofing or water-tight material placed above the thermal insulation on top of the metal roof deck serves to maintain this insulation also in. effective or dry condition by excluding liquid water therefrom.

While the invention has been described particularly as applied to the construction of a ceiling or to a side wall, it should be understood 'that other uses may be made of this sound-deadening structure. The inverted and perforated metal deck filled with sound-deadening material may be used to span the under side of girders, trusses, and the like, to form a sound-deadening and heat insulating in certain types of hired ceiling construction. we

The detailswhich have been given are for the purpose of. illustration rather than limitation of the invention. Thus the sound-deadening material may consist. of many materials other than the :rock wool which has been mentioned. The sounddeadening material may comprise, for example, asbestos fiber in porous and permeable form, cane fiber board with a multiplicity of holes sunk there- 'in to give a product sold for acoustical purposes, felts of various kinds adapted to deaden or absorb sound, or permeable and porous ceramic tile. While loose felts may be used, rigid. or semi-rigid sound-deadening material in the form of preformed units or panels is particularly desirable 'inthe structures of the present invention. The term sound-deadening" is used herein to include what is frequently called "sound-absorption. The sound-deadening material used should be relatively effective, by which is meant that the sound-deadening material should deaden or absorb more than 4 per cent and 'and blowing an argillaceous limestone.

suitably 50 to 90 percent or more'of incident soundof approximately 500 cycles frequency.

. The superposed protective material consisting of lnsulatingboard protected from rain by asphalt-impregnated roofing paper has been de-,'

scribed. Other'thermal insulating materials may be used, as, for example, sheets of .vegetable cork, compositions comprising asbestos, mineral wool, on other effective thermal insulating material. However, particularly satisfactory results have been-obtained when the thermal insulating material hasconsiderable rigidity. This rigidity of the protective material serves to increase the rigidity of the whole structure so that a man may walk over a typical roof constructed in accord ance with the present invention. I

It will be understood that the term rock wool, as usedherein represents a product of melting While other mineral wool, such as slag wool, may be used in place of rock wool, the rock wool is prefen-ed, in part, because of the greater stability of the latter when exposed to air. I

'Some' of the binding materials used in the sound-deadening panels are affected -by water and particularly -by alternate wetting and drying out of the panel. This is particularly true when various glue or modified starch binders are used. For this reason also the action of the protective layers of the thermal insulating and waterproof-- ing materialsin excluding water from the sounddeadening aterials is desirable.

- The multiplicity of perforations adapted to admit incident sound, with which the metal'deck is provided, communicate with the pores in the sound-deadening material maintained in position above the perforations.' This permits the entrance of incient sound through the perforation? and into the pores of the sound deadener. The imperforate ribs, on the other hand, prevent or minimize lateral circulation of air thr ugh sound absorbing material disposed between t e ribs.

Reference has been made to the use of imperforate metal sheeting, as illustrated inFigs. 7- and 8, for placement-over the back of the sounddeadening material, that is, the surface remote from the perforated sheeting. The term imperforate excludes sheeting provided with a;

multlpllciiy of perforations adapted to admit soundybut. does not exclude sheets perforated to receive rivets bolts, for-example, or in such a spouse manner as not to adapt the'sheet'to sdmwremily sound which isincident upon the sheet. Ihe stmctures of the present inventionare to be distinguished from a conventional acoustical,

ceiling which requires protection by an independent roof structure. According to my invention the acoustical'ceiling and the roof are combined in one structure. 1 Since many variations from the illustrative details given may be made without departing from the scope of the invention, it is intended that the invention should be limited only by the terms of the claims interpreted as broadly as consistent with novelty over the prior art.

What I claim is: 1 1. A sound-deadening roof comprising in combination a supporting sub-structure, a metal deck in the form of sections provided each with a plu-Y rality of imperforate integral beams, flat portions of said deck, intermediate the beams, provided with a multiplicity of perforations adapted to admit incident sound. relatively effective sounddeadening material maintained in position above the perforations and between the beams, and a layer of thermal insulating material placed above the sound-deadening material and adaptedto maintain the sdunddeadening material in effective condition.

2. A sound-deadening roof comprising in combination a supporting substructure. a metal deck in the form of sections provided each with a plurality of imperforate integralbeams, flat portions of said deck, intermediate the beams, provided' with a multiplicity ofperforations adapted to admit incident sound, relatively effective sound-deadening material maintained in position above the perforations, and layers of thermal insulating and water-tight materials placed above the, sound-deadening material and adapted to maintain the sound-deadening material in effective condition.

' 3. A sound-deadening roof including in combination. supporting substructure, a metal deck comprising upwardly extending integral beams and flat portions provided with a multiplicity-of perforations adapted to admit incident sound.

relatively effective sound-deadening placed above said perforations and between the beams, and superposed protective material supported upon the said beams and adapted to main? tain the sound-deadening material in effective condition.

4. A sound-deadening roof including in combination a supporting substructure, a metal deck comprising integral beams and gat portions pro:

vided with a multiplicity of perforations adapted to admit' incident sound, relatively effective sound-deadening material in the form of rigid panels placed above said perforations, superpo'sed protective material adapted to maintain the sounddeadening material in effective condimaterial from the perforated portions of the saiddecln 5. A sound-deadening roof including in combination a supporting substructure, a metal deck spaced relationship to the beams of the perfotion, and means for spacing the sound-deadening -comprising upwardly extending integral beams rated roof deck, whereby the thermal transmis of said deck, intermediate the beams, provided with a multiplicity of perforations adapted to admit incident sound, and sound-deadening material maintained in position above the perforations;

7. A sound-deadening roof comprising in combinatlona supporting substructure, a metal deck in the form of sections having each a plurality of imperi'orate upwardly extending integral beams and flat" portions of said deck, intermediate the beams, provided with a multiplicity of perforations adapted to admit incident sound, and sounddeadening material maintained in position above the perforations and between-the beams, whereby lateral circulation of air through the sounddeadening material is minimized.

8. A sound-deadening roof comprising in combination a supporting substructure, a metal deck in the form of sections having each a plurality of imperforate integral beams and flat portions of the said deck, intermediate the ribs, provided with a multiplicity of perforations adapted to admit incident sound. relatively effective sound deadening material maintained in position above the perforations, and a protective material disposed above the sound-deadening material and adapted to maintain the sound-deadening mal6 terial in effective condition.

GEORGE D. KEILOGG. 

